Skylight and method of fabricating the same

ABSTRACT

A skylight system including a support frame and an apex patch fitting that together support a plurality of glass pieces joined together in a selectable shape. The support frame includes a sill and a setting chair that are arranged to support the base portions of the glass pieces. The apex patch fitting may be of selectable shape and includes an upper and lower member to retain the peaks or corners of the glass therebetween. The apex patch fitting includes one or more positioning keys to align and secure the glass pieces. A method of making the skylights includes the use of an apex retainer tool to maintain the apex patch fitting in a fixed position while placing glass pieces on it. Multiple apex patch fittings can be used for a skylight, including a skylight that is ridge shaped or hipped ridge shape.

The present application is a divisional application, and claims thepriority benefit, of U.S. nonprovisional patent application is Ser. no.13/833,812 filed Mar. 15, 2013, entitled “SKYLIGHT AND METHOD OFFABRICATING THE SAME” of the present applicant and with the same namedinventors, The entire content of the prior application is incorporatedherein by reference.

BACKGROUND OF INVENTION

1. Field of the Invention

The present invention relates to skylights and methods for makingskylights. More particularly, the present invention relates tocommercial skylights but is not limited to that.

2. Description of the Prior Art

For years, the commercial skylight industry has offered relativelylimited options for customers in terms of materials, aesthetics andperformance. Their aging design has not kept up with rapidly evolvingstandards for energy efficiency, green building practices, and costcontrols. New standards demand maximum daylighting benefits and acontribution to the overall energy efficiency of the building.Additionally, architects continually demand greater flexibility inaesthetics, materials and simplicity of design.

Traditional skylights are typically offered with glass or acrylicpanels. They range in shape from plastic bubbles, to flat “single slope”rectangles, and a range of complex shapes including pyramids, polygonsand ridges, and custom shapes. Current skylight systems are relativelysimilar from manufacturer to manufacturer, making them difficult todifferentiate. Typical construction relies on a grid of aluminumrafters, which limits viewable area, requires hundreds of parts andpieces, and reduces overall performance.

It is known in the field of skylights and other building areas wherestructural glass is a feature to use patch fittings as a way to secureadjacent pieces of glass together or to reinforce the perimeter orportions of the perimeter of the glass. Patch fittings comprise twopieces of metal or similar structural material joined together tosandwich the glass between them. Patch fittings that currently existjoin the two metal pieces together around the glass piece with a bolt orscrew and may include a gasket on the interior surfaces to space themetal from the glass. It is also known in the field of skylights thathave an apex to use an apex cap to conceal the intersection wheremultiple pieces of glass come together. The apex cap may be metal orother material but is essentially a decorative item rather than astructural item. The apex cap may be useful to minimize moistureintrusion through the skylight. It is believed that there is no apexcover for a skylight that is also a structural member to support and/orconstrain glass pieces of the skylight. In other words, there iscurrently no “apex patch fitting.”

What is needed is a skylight system that can be made in a variety ofconfigurations with suitable structural integrity and minimal visualobstruction. Further, what is needed is a skylight system that isrelatively easy to make and can be made with a minimum number of parts.Further, what is needed is a method of making a skylight in place andcomponents and instructions to create such skylights.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a skylight systemthat can be made in a variety of configurations with suitable structuralintegrity and minimal visual obstruction. It is also an object toprovide a skylight system that is relatively easy to install and can beassembled with a minimum number of parts. It is another object of thepresent invention to provide a method of making a skylight in place andcomponents and instructions to create such skylights.

These and other objects are achieved with the present invention, whichis a skylight system including a support frame at the base only, asetting chair, an apex patch fitting and a plurality of structural glasspieces fitted to the support frame and spaced from one another by asealing interface. The apex patch fitting and the support frame providesupport for the glass pieces and are configured, along with the sealinginterface, to seal the edges of the glass pieces against moisture andthermal infiltration through the skylight. The invention is also, moregenerally, a skylight with one or more apex patch fittings. It isbelieved that prior to the present invention, the apex of any skylightmay have been covered simply with a decorative apex cap to conceal theintersecting framing members and provide a moisture barrier. The use ofan apex patch fitting has not been provided prior to the presentinvention. Further, it is an apex patch fitting configured as describedherein, whether a skylight or other glass structure having such an apexpatch fitting includes the support frame or the sealing interfacedescribed herein.

An embodiment of the skylight system invention is a skylight including asupport frame at the base only having N sides, wherein each sideincludes a glass support sill, N pieces of glass, wherein each pieceincludes a base and a peak, wherein the base of each piece of glass ispositioned on respective ones of the glass support sills of the sides ofthe support frame, and an apex patch fitting including N slots, whereineach slot is configured to receive and retain therein respective ones ofthe peaks of each of the pieces of glass, wherein the apex patch fittingand the support frame support the pieces of glass. The skylight may alsoinclude N ridge sealing components configured to fit between adjacentones of the pieces of glass when the pieces of glass are positioned onthe support frame and in the apex patch fitting. The use of the apexpatch fitting designed as described herein reduces the need to makelarge, wide support frames beneath the glass that impeded the view fromunder the skylight. The ridge sealing components include a flexiblebacker rod configured to fit between adjacent pieces of glass betweenupper and lower members thereof.

The glass pieces have an upper surface and a lower surface. The lowersurface may include an extension so that when two pieces of glass areadjacent to one another, a spacing between the lower surfaces isapproximately equal to the spacing between the upper surfaces. The apexpatch fitting includes an upper body, a lower body and a positioning keythat joins together the upper body and the lower body. The positioningkey spaces the upper body from the lower body. The upper body and thelower body extend to cover an upper space and a lower space betweenadjacent pieces of glass. The skylight includes a plurality of settingchairs corresponding in number to the number of glass pieces andarranged to space the base of each piece of glass from its respectiveglass support sill.

The skylight of the present invention may be formed in a variety ofshapes, including pyramidal, polygonal, ridge and hipped ridge. A singleslope skylight may also be made with the present invention. The ridgeand hipped ridge may be of selectable length. Multiple apex patchfittings and apex patch fittings that account for different peakinterfaces are provided with the present invention.

The skylights of the present invention may be fabricated and assembledwith great ease using the base support frame and apex patch fittingdescribed herein, as well as an apex patch fitting support tool thatfacilitates glass placement on the support frame and into the apex patchfitting. The support frame and apex patch fitting designs, as well asglass interface sealing components, ensure a high quality skylight ofselectable dimensions and effective thermal and moisture intrusionprevention. Visibility through the skylight is maximized with thepresent invention. These and other features and advantages of thepresent invention will be understood upon review of the followingdetailed description, the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a first embodiment of the skylightof the present invention in a pyramid configuration.

FIG. 2 is a top plan view of the skylight of FIG. 1.

FIG. 3 is a perspective view of the apex patch fitting of the presentinvention in position at the peak of the skylight of FIG. 1.

FIG. 4 is a top plan view of the apex patch fitting for the skylight ofFIG. 1.

FIG. 5 is a bottom plan view of the apex patch fitting for the skylightof FIG. 1.

FIG. 6 is a side view of the sill for the skylight of FIG. 1 at thecorner thereof and showing the sill partially in cross section.

FIG. 7 is a first cross sectional side view of the apex patch fittingfor the skylight of FIG. 1.

FIG. 8 is a second cross sectional side view of the apex patch fittingfor the skylight of FIG. 1.

FIG. 9 is a third cross sectional side view of the apex patch fittingfor the skylight of FIG. 1.

FIG. 10 is a cross sectional side view of an interface between twopieces of glass showing the hip sealing component for the skylight ofFIG. 1.

FIG. 11 is a perspective view of a second embodiment of the skylight ofthe present invention in a polygon configuration.

FIG. 12 is a top plan view of the skylight of FIG. 11.

FIG. 13 is a cross sectional side view of the sill of the skylight ofFIG. 11 at the corner thereof and partially in cross section.

FIG. 14 is a perspective view of the apex patch fitting for the skylightof FIG. 11.

FIG. 15 is a top plan view of the apex patch fitting for the skylight ofFIG. 11.

FIG. 16 is a bottom plan view of the apex patch fitting for the skylightof FIG. 11.

FIG. 17 is a perspective view of a third embodiment of the skylight ofthe present invention in a ridge configuration.

FIG. 18 is a top plan view of the skylight of FIG. 17.

FIG. 19 is a cross sectional side view of the apex patch fitting for theskylight of FIG. 17.

FIG. 20 is a top plan view of the apex patch fitting for the skylight ofFIG. 17.

FIG. 21 is a bottom plan view of the apex patch fitting for the skylightof FIG. 17.

FIG. 22 is a cross sectional side view of an interface between twopieces of glass of the skylight of FIG. 17 at the ridge showing theridge sealing component.

FIG. 23 is a cross sectional side view of the end sill apex for theskylight of FIG. 17.

FIG. 24 is a cross sectional side view of the sill for the skylight ofFIG. 17 at the corner thereof and partially in cross section.

FIG. 25 is a cross sectional side view of the sill splice for theskylight of FIG. 17.

FIG. 26 is a cross sectional side view of the butt joint for theskylight of FIG. 17.

FIG. 27 is a perspective view of a fourth embodiment of the skylight ofthe present invention in a hipped ridge configuration.

FIG. 28 is a top plan view of the skylight of FIG. 27.

FIG. 29 is a cross sectional side view of a first apex patch fitting forthe skylight of FIG. 27.

FIG. 30 is a top plan view of the first apex patch fitting for theskylight of FIG. 27.

FIG. 31 is a bottom plan view of the first apex patch fitting for theskylight of FIG. 27.

FIG. 32 is a cross sectional side view of a second apex patch fittingfor the skylight of FIG. 27.

FIG. 33 is a top plan view of the second apex patch fitting for theskylight of FIG. 27.

FIG. 34 is a bottom plan view of the second apex patch fitting for theskylight of FIG. 27.

FIG. 35 is a cross sectional side view of the sill for the skylight ofFIG. 27 at the corner thereof and partially in cross section.

FIG. 36 is a cross sectional side view of the glass pieces interface atthe peak for the skylight of FIG. 27.

FIG. 37 is a cross sectional side view of the glass pieces interface atthe hip transition for the skylight of FIG. 27.

FIG. 38 is a perspective view of the support frame used in making apyramid-shaped skylight.

FIG. 39 is a perspective view of the glass installation support used inmaking the pyramid-shaped skylight.

FIG. 40 is a perspective view of two pieces of glass on the installationsupport as part of the process used in making the pyramid-shapedskylight.

FIG. 41 is a perspective view of the pyramid-shaped skylight using theassembly process of the present invention.

DETAILED DESCRIPTIONS OF SEVERAL EMBODIMENTS OF THE INVENTION

A first embodiment of a skylight system 10 of the present invention isshown in FIGS. 1-10. A second embodiment of a skylight system 200 of thepresent invention is shown in FIGS. 11-16. A third embodiment of askylight system 400 of the present invention is shown in FIGS. 17-26. Afourth embodiment of a skylight system 600 of the present invention isshown in FIGS. 27-37. All of the embodiments of the skylight systemrepresent substantial improvements over existing skylight systems inthat they provide greater flexibility, good thermal and moistureisolation and ease of fabrication and assembly. The four skylightsystems represent four different skylight shapes. The first skylightsystem 10 forms a skylight of pyramid shape. The second skylight system200 forms a skylight of polygon shape (8-sided in the particular versiondescribed herein but not limited to that specific number of sides). Thethird skylight system 400 forms a skylight of ridge shape. The fourthskylight system 600 forms a skylight of hipped ridge shape.

The pyramid-shaped skylight formed of the skylight system 10 representedin FIGS. 1-10 includes four pieces of glass 11, 12, 14 and 16 retainedon a support frame 18. The glass pieces 11-16 are further retainedtogether in an angled position with respect to the support frame 18 withan apex patch fitting 20. Each of the glass pieces 11-16 is ofsubstantially the same dimensions. They are triangular in shape,including a base 22 and a peak 24. Each piece forms one quarter of thecoverage of the skylight. The base 22 of each piece of glass is set onand retained to the support frame 18 and the peak 24 of each piece ofglass is set in and retained to the apex patch fitting 20. Each piece ofglass is spaced from an adjacent piece of glass by a hip sealingcomponent 26. The pieces of glass 11-16 are sized to create the skylightof desired size.

The support frame 18 is a square including four sections 28, 30, 32 and34, wherein each section 28-34 supports an individual one of the glasspieces 11-16. Each of the four sections 28-34 includes a sill member 36,a setting chair 38, and one or more setting blocks 40. These componentsof the four sections 28-34 are separable but one or more may be part ofa unitary structure. The sill member 36 is a shaped piece that may befabricated of Aluminum or other material suitable to withstand anoutside environment for a long period of time. Each sill member 36 has alength that is slightly more than the length of the base 22 of one ofthe glass pieces 11-16. The sill member 36 includes a first leg 42, asecond leg 44, a third leg 46 and a fourth leg 48. The first leg 42 isconfigured to rest on an underlying surface 50 where the skylight is tobe installed. The first leg 42 includes a condensate trap flange 52 toestablish a condensation evaporation channel 54. A sill attachmentelement, such as a threaded bolt 56, is used to fixedly attach the sillmember 36 to the underlying surface 50.

The second leg 44 of the sill member 36 extends upwardly at a rightangle from end 58 of the first leg 42. The second leg 44 has an angledupper section 60 that extends to the third leg 46. The third leg 46extends downwardly from the upper section 60 of the second leg 44 andterminates at a chair retaining region 62. The chair retaining region 62includes a chair support slot 64 that includes an inlet section 66 and aretaining shoulder 68 with an underlying retaining space 70, thecombination of which provides a retainer for setting the position of thesetting chair 38. A glass piece of the glass pieces 11-16 of theskylight is set on surface 72 of the third leg 46.

The fourth leg 48 extends downwardly from the chair retaining region 62of the third leg 46. The fourth leg 48 terminates with an insulationsupport flange 67, which also acts as a sealing surface. The fourth leg48 is substantially parallel to the second leg 42 but it is shorter thanthe second leg 42. When the sill member 36 is in position on the surface50, the fourth leg 48 does not contact the surface 50. The difference inthe height of the fourth leg 48 at the chair retaining region 62 and thesecond leg 44 at the upper section 60 defines the angle of the glasspiece when in position on the surface 72 of the third leg 46 withrespect to the underlying surface 50. In the version of thepyramid-shaped skylight represented in FIGS. 1-10, that angle is about30°. Other angles are possible and may be established by the heightdifference between the second leg 44 and the fourth leg 48. Space 65between the second leg 44 and the fourth leg 48 may be filled withinsulation if desired.

The system 10 further includes for each of the four corners of theskylight a substantially right angle corner key 74. The corner key 74 isa bar that when placed at an interface of adjacent ones of the sections28-34 sets the corner and joins those sections together with attachmentelements such as threaded bolts 76. The corner key 74 is configured tofit into corner key slot 78 located at underside 80 of third leg 46adjacent to second leg 44. Each leg of the corner key 74 extends aboutthree inches along the length of adjacent ones of sections 28-34 but isnot limited thereto.

The setting chair 38 is a substantially flat bar that includes a base 82extending its entire length. The setting chair 38 has a lengthsubstantially the same as the sill member 36. The base 82 includes aretaining flange 84 and a retaining nose 86. When the setting chair 38is set in position on the sill member 36, the retaining nose 86 extendsinto the inlet section 66 under the retaining shoulder 68 and into theretaining space 70 of the third leg 46 of the sill member 36. At thattime, the retaining flange 84 rests on the edge of the interface of thethird leg 46 and the fourth leg 48 of the sill member 36.

The setting chair 38 establishes the perimeter and support for the base22 of the glass piece. The base 22 is separated from the setting chair38 by one or more setting blocks 40 that are positioned in space 88. Thesetting blocks 40 may extend substantially the entire length of thesetting chair 38 or it may be established by a plurality of pieces thatare spaced from one another along the length of the setting chair 38.The base 22 of the glass piece may be joined to the sill member 36 withstructural glazing tape or structural silicone, for example.

The base 22 of each of the glass pieces 11-16 rests on the settingblocks 40 and each of the pieces extends to an apex 90 where the peaks24 of each glass piece 11-16 are retained together with the apex patchfitting 20. The apex patch fitting 20 includes an outer patch member 92and an inner patch member 94 establishing a patch space 96 therebetween.An underside 98 of the outer patch member 92 and an upper side 100 ofthe inner patch member 94 includes an apex patch fitting gasket 102affixed thereto. The distance between the gasket 102 of the outer patchmember 92 and the gasket 102 of the inner patch member 94 is determinedby the thickness of the glass pieces 11-16. The apex patch fittingmembers 92 and 94 are joined together with joining members such asthreaded bolts 104 that are located between adjacent pieces of glass11-16.

The patch space 96 is further established by one or more patchpositioning keys 106. Two are shown in the side view of FIG. 9. Ingeneral, the number of patch positioning keys 106 of the apex patchfitting 20 may correspond in number to the number of glass piecessecured to the apex patch fitting 20, although deviation from that ratiois possible in some situations. This comment applies for all apex patchfittings and patch positioning keys described herein. The patchpositioning key 106 is a shaped element having an upper section 108 anda lower section 110. The upper section 108 is essentially in the form ofan annulus, with an upper pilot hole 120 for receiving a retainingelement such as threaded bolt 112, which joins the positioning key 106to the outer patch member 92. The lower section 110 is trapezoidal inshape so that its perimeter 114 is substantially in parallel with innerpeak section 116 of the peaks 24 of the glass pieces 11-16 and spacedtherefrom by flexible patch block 118. The lower section has two lowerpilot holes 121 for receiving the retaining element such as threadedbolt 112 to join the positioning key 106 to the inner patch member 94.As shown in FIG. 9, each patch positioning key 106 has three pilot holesin total, for receiving therein one retaining element through the outerpatch member 92 and two retaining elements through inner patch member94. With the glass peaks 24 placed between the outer member 92 and theinner member 94 and the positioning key 106 in the patch space 96, theglass pieces 11-16 may be adjusted until in a desired position beforethe joining elements 104 are secured to the respective members 92 and 94and the glass pieces 11-16 fixed in place.

The configuration of the apex patch fitting 20 with the patchpositioning key 106, and more generally for all of the apex patchfittings with patch positioning keys described herein, establishesstructural support for glass. This configuration may be used at an apexof a skylight or other type of glass structure. The configuration of apatch fitting with a patch positioning key as described may moregenerally be used to secure one or more glass pieces, whetherspecifically at an apex of a structure or not.

Spaces 124 between adjacent glass pieces 11-16 are sealed with the hipsealing component 26 that includes an interior trim gasket 128 and abacker rod 130. The trim gasket 128 and the backer rod 130 extendsubstantially the length of the space 124. The trim gasket 128 is madeof a relatively soft material, such as rubber having a hardness of about70 Shore A durometer. The trim gasket 128 is a shaped piece includingflexible legs 132 that, with the softness of the material, ensures thatthe gasket 128 remains in substantial contact with ends 134 and 136 ofadjacent pieces of glass even if the space between varies to an extentfrom one end to the other of the space 124. The gasket 128 may befabricated of other materials and of different shapes as long as thatgap filling element takes up the area of the space 124 between the innerportions of adjacent pieces of glass sufficiently to provide areasonable thermal seal.

The backer rod 130 is used to fill a portion of the space 124 in middleand outer regions between the adjacent pieces of glass with aninsulative material that provides a substrate for a sealing material,such as silicone, to provide an outer seal 138 of the hip sealing member26. Prior configurations of such types of skylights not only had largemetal pieces to enclose the space 124. The metal used to fill the gap insuch prior configurations would facilitate thermal transfer from outsideto inside. The backer rod 130 is flexible enough to accommodate anglevariances between infill panels (glass shown here) and facilitates theuse of cured sealants such as silicone.

The polygon-shaped skylight formed of the skylight system 200represented in FIGS. 11-16 includes eight pieces of glass 202, 204, 206,208, 210, 212, 214 and 216 retained on a support frame 218 wherein thepolygon is a peaked octagonal shape. It is to be understood that thepolygon may have more or fewer sides and the description of the octagonform substantially remains the same for other polygons. the glass pieces202-216 are further retained together in an angled position with respectto the support frame 218 with an apex patch fitting 220. Each of theglass pieces 202-216 is of substantially the same dimensions. They aretriangular in shape, including a base 222 and a peak 224. Each pieceforms one eight of the coverage of the skylight. The base 222 of eachpiece of glass is set on and retained to the support frame 218 and thepeak 224 of each piece of glass is set in and retained to the apex patchfitting 220. Each piece of glass is spaced from an adjacent piece ofglass by a hip sealing member 226. The pieces of glass 202-216 are sizedto create the skylight of desired size.

The support frame 218 is an octagon including eight sections 228, 230,232, 234, 236, 238, 240 and 242, wherein each section 228-242 supportsan individual one of the glass pieces 202-216. Each of the sections228-242 includes a sill member 244, a setting chair 246, and one or moresetting blocks 248. These components of the sections 228-242 areseparable but one or more may be part of a unitary structure. The sillmember 244 is a shaped piece that may be fabricated of Aluminum or othermaterial suitable to withstand an outside environment for a long periodof time. Each sill member 244 has a length that is slightly more thanthe length of the base 222 of one of the glass pieces 202-216. The sillmember 244 is essentially the same as the sill member 46 of the system10. It includes a first leg 250, a second leg 252, a third leg 254 and afourth leg 256. The first leg 250 is configured to rest on an underlyingsurface 258 where the skylight is to be installed. The first leg 250includes a condensate trap flange 260 to establish a condensationevaporation channel 262. A sill attachment element, such as a threadedbolt 264, is used to fixedly attach the sill member 244 to theunderlying surface 258.

The second leg 252 of the sill member 244 extends upwardly at a rightangle from end 266 of the first leg 250. The second leg 252 has anangled upper section 268 that extends to the third leg 254. The thirdleg 254 extends downwardly from the upper section 268 of the second leg252 and terminates at a chair retaining region 270. The chair retainingregion 270 includes a chair support slot 272 that includes an inletsection 274 and a retaining shoulder 276 with an underlying retainingspace 278, the combination of which provides a retainer for setting theposition of the setting chair 246. A glass piece of the glass pieces202-216 of the skylight is set on surface 280 of the third leg 254.

The fourth leg 256 extends downwardly from the chair retaining region270 of the third leg 254. The fourth leg 256 terminates with aninsulation support flange 282, which also acts as a sealing surface. Thefourth leg 256 is substantially parallel to the second leg 252 but it isshorter than the second leg 252. When the sill member 244 is in positionon the surface 258, the fourth leg 256 does not contact the surface 258.The difference in the height of the fourth leg 256 at the chairretaining region 270 and the second leg 252 at the upper section 268defines the angle of the glass piece when in position on the surface 280of the third leg 254 with respect to the underlying surface 258. In theversion of the octagon-shaped skylight represented in FIGS. 11-16, thatangle is about 30°. Other angles are possible and may be established bythe height difference between the second leg 252 and the fourth leg 256.Space 283 between the second leg 252 and the fourth leg 256 may befilled with insulation if desired.

The system 200 further includes for each of the eight vertices of theskylight a corner key 284 having an inside angle of about 135°. Thecorner key 284 is an angled bar that when placed at an interface ofadjacent ones of the sections 228-242 sets the vertex and joins thosesections together with attachment elements such as threaded bolts 286.The corner key 284 is configured to fit into corner key slot 286 locatedat underside 288 of third leg 254 adjacent to second leg 252. Each legof the corner key 284 extends about three inches along the length ofadjacent ones of sections 228-242 but is not limited thereto.

The setting chair 246 is a substantially flat bar that includes a base290 extending its entire length. The setting chair 246 has a lengthsubstantially the same as the sill member 244. The base 290 includes aretaining flange 292 and a retaining nose 294. When the setting chair246 is set in position on the sill member 244, the retaining nose 294extends into the inlet section 274 under the retaining shoulder 276 andinto the retaining space 276 of the third leg 254 of the sill member244. At that time, the retaining flange 292 rests on the edge of theinterface of the third leg 254 and the fourth leg 256 of the sill member244.

The setting chair 246 establishes the perimeter and support for the base222 of the glass piece. The base 222 is separated from the setting chair246 by one or more setting blocks 248 that are positioned in space 282.The setting blocks 248 may extend substantially the entire length of thesetting chair 246 or it may be established by a plurality of pieces thatare spaced from one another along the length of the setting chair 246.The base 222 of each piece of glass may be joined to the sill member 244with structural glazing tape or structural silicone, for example.

The base 222 of each of the glass pieces 202-216 rests on the settingblocks 248 and each of the pieces extends to an apex 296 where the peaks224 of each glass piece 202-216 are retained together with the apexpatch fitting 220. The apex patch fitting 220 includes an outer patchmember 298 and an inner patch member 300 establishing a patch spacetherebetween. Except with respect to its particular size and shape, theapex patch fitting 220 is configured essentially the same as the apexpatch fitting 20 of the system 10 shown in FIGS. 1-11. In particular, anunderside of the outer patch member 298 and an upper side of the innerpatch member 300 includes an apex patch fitting gasket affixed thereto.The distance between the gasket of the outer patch member 298 and thegasket of the inner patch member 300 is determined by the thickness ofthe glass pieces 202-216. The apex patch fitting members 298 and 300 are joined together with joining members such as threaded bolts 302 thatare located between adjacent pieces of glass 202-216.

The space between the outer member 298 and the inner member 300 isfurther established by the patch positioning key previously described,which description is incorporated herein. With the glass peaks 224placed between the outer member 298 and the inner member 300 and thepositioning key in the patch space, the glass pieces 202-216 may beadjusted until in a desired position before the joining elements 302 aresecured to the respective members 298 and 300 and the glass pieces202-216 fixed in place. Spaces between adjacent glass pieces 202-216 aresealed with the hip sealing member 226 that includes the same componentsand corresponds with the function and configuration of the hip sealingmember 26 of the system 10. The description of the hip sealing member26, including reference to the trim gasket and the backer rod, isincorporated here with respect to the arrangement and function of thehip sealing member 226.

The ridge-shaped skylight formed of the skylight system 400 representedin FIGS. 17-26 includes 12 pieces of glass 402-424 retained on a supportsystem 426. This is just one example of a ridge-shaped skylight. Otherversions with more or fewer pieces of glass are contemplated. Each ofthe glass pieces 402-424 are further retained together in an angledposition with respect to the support system 426 with apex patch fittings428-436, one at each intersection of the peaks of four pieces of glasssimilar to the configuration of the apex patch fitting 20 of system 10.Each of the glass pieces 402-424 is of substantially the same dimensionsas shown; however, they may vary. Each piece of glass is substantiallysquare in shape and includes a base side 438, a peak side 440 opposingthe base side 438 and two opposing sides 442 and 444. Each piece forms asection of coverage of the skylight. It is to be noted that theconfiguration of the combination of components of the system 400 may beused to make a skylight that extends for any selectable length to formthe entire ridge of a building structure having almost any length. Thatis, the system 400 can be used to replace the roof ridge of a building.

The base side 438 of each piece of glass is set on and retained to thesupport system 426 and the peak side 440 of each piece of glass is setin and retained to a corresponding one of the apex patch fittings428-436. Each piece of glass is spaced from an adjacent piece of glassby a ridge sealing component 446. The pieces of glass 402-424 are sizedto create the skylight of desired size.

The support system 426 includes a first base support 448, a second basesupport 450, a first edge support 452 and a second edge support 454. Thefirst base support 448 is configured to support the base side 438 ofglass pieces 402-412 and the second base support 450 is configured tosupport the base side 438 of glass pieces 414-424. The first edgesupport 452 is configured to support the opposing side 442 of glasspieces 402 and 414, and the second edge support 454 is configured tosupport the opposing side 444 of glass pieces 412 and 424. As noted,additional glass pieces may be added on each side of a roof peak and thefirst base support 448 and the second base support 450 would simply beextended.

Each of the first base support 448 and the second base support 450 ismade up of a plurality of individual base support sections 456 whereinindividual base support sections 456 may span and support multiple glasspieces. Each base support section 456 includes a sill member 458, asetting chair 460, and one or more setting blocks 462. These componentsof the base support section 456 are separable but one or more may bepart of a unitary structure. The sill member 458 is a shaped piece thatmay be fabricated of Aluminum or other material suitable to withstand anoutside environment for a long period of time. The sill member 458includes a first leg 464, a second leg 466, a third leg 468 and a fourthleg 470. The first leg 464 is configured to rest on an underlyingsurface 472 where the skylight is to be installed. The first leg 464includes a condensate trap flange 474 to establish a condensationevaporation channel 476. A sill attachment element, such as a threadedbolt 478, is used to fixedly attach the sill member 458 to theunderlying surface 472.

The second leg 466 of the sill member 458 extends upwardly at a rightangle from end 480 of the first leg 464. The second leg 466 extends at aright angle away from the first leg 464 to the third leg 468. The thirdleg 468 extends from the second leg 466 and terminates at a chairretaining region 482. The chair retaining region 482 includes a chairsupport slot 484 that includes an inlet section 486 and a retainingshoulder 488 with an underlying retaining space 490, the combination ofwhich provides a retainer for setting the position of the setting chair460. A glass piece of the glass pieces 402-424 of the skylight is set onsurface 492 of the third leg 468.

The fourth leg 470 extends downwardly at a right angle from the chairretaining region 482 of the third leg 468. The fourth leg 470 terminateswith an insulation support flange 494, which also acts as a sealingsurface. The fourth leg 470 is substantially parallel to the second leg466 but it is shorter than the second leg 466. When the sill member 458is in position on the surface 472, the fourth leg 470 does not contactthe surface 472. The configuration of the sill member 458 establishesthe position of the glass piece as substantially parallel to theunderlying surface 472. Space 496 between the second leg 466 and thefourth leg 470 may be filled with insulation if desired.

The first edge support 452 and the second edge support 454 each includesa respective set of two edge support sections 498. Each edge supportsection 498 supports a respective one of opposing side 442 of glasspieces 402, 412, 414 and 424. Each edge support section 498 supports therespective sides 442 of each of those pieces of glass in the way thatthe base support sections 456 support the base sides 438 of the glasspieces 402-424. They include an end sill member, an end setting chairand one or more end setting blocks, each corresponding to the sillmember 458, the setting chair 460, and the one or more setting blocks462 described herein. Each of the edge support sections 498 includescorner transitions where the edge support sections 498 are joined to thebase support sections 456 of glass pieces 402, 412, 414 and 424. Thatjoining is accomplished using at each of those corner interfaces asubstantially right angle corner key 500. The corner key 500 is a barthat when placed at the interface of the edge support sections 498 andthe base support sections 456 where indicated. It sets the corner andjoins those sections together with attachment elements such as threadedbolts 502. The corner key 500 is configured to fit into corner key slot504 located at underside 506 of third leg 468 adjacent to second leg464. Each leg of the corner key 500 extends about three inches along thelength of adjacent ones of sections 456 and 498 but is not limitedthereto.

For the glass base and edge supports, the setting chair 460 is asubstantially flat bar that includes a base 508 extending its entirelength. The setting chair 460 has a length substantially the same as thesill member 458. The base 508 includes a retaining flange 510 and aretaining nose 512. When the setting chair 460 is set in position on thesill member 458, the retaining nose 512 extends into the inlet section486 under the retaining shoulder 488 and into the retaining space 490 ofthe third leg 468 of the sill member 458. At that time, the retainingflange 510 rests on the edge of the interface of the third leg 468 andthe fourth leg 470 of the sill member 458.

The setting chair 458 establishes the perimeter and support for the baseside 438 of all of the glass pieces and the opposing side 442 of edgeglass pieces 402, 412, 414 and 424. The base side 438 and the opposingside 442 are each separated from the setting chair 458 by one or moresetting blocks 462 that are positioned in space 511. The setting blocks462 may extend substantially the entire length of the setting chair 458or they may be established by a plurality of pieces that are spaced fromone another along the length of the setting chair 458. The base side 438and the opposing side 442 may be joined to the sill member 458 withstructural glazing tape or structural silicone, for example.

The base side 438 of each of the glass pieces 402-424 rests on thesetting blocks 462 and each of the pieces extends to an apex 514 whereinterior corners 516 of the peak side 440 of each glass piece 402-424are retained together by a respective one of apex patch fittings 428-436in sets of four where those corners meet. Each of the apex patchfittings 428-436 includes an outer patch member 518 and an inner patchmember 520 establishing a patch space 526 therebetween. An underside 528of the outer patch member 518 and an upper side 530 of the inner patchmember 520 includes an apex patch fitting gasket 522 affixed thereto.The distance between the gasket 522 of the outer patch member 518 andthe gasket 522 of the inner patch member 520 is determined by thethickness of the glass pieces 402-424. The apex patch fitting members518 and 520 are joined together with joining members such as threadedbolts 534 and 544 that are located between adjacent pieces of glass402-424. There may also be anti-walk setting blocks 524 between theglass pieces at these locations.

The patch space 526 is further established by one or more patchpositioning keys 528. The patch positioning key 528 is a shaped elementhaving an upper section 530 and a lower section 532. The upper section530 is essentially in the form of an annulus, with an upper pilot hole537 for receiving a retaining element such as threaded bolt 534, whichjoins the positioning key 528 to the outer patch member 518. The lowersection 532 is trapezoidal in shape so that its perimeter 536 issubstantially in parallel with inner peak section 538 of the interiorcorners 516 of the peak sides 440 of the glass pieces 402-424 and spacedtherefrom by flexible patch block 540. the lower section 532 has twolower pilot holes for receiving therein a retaining element such asthreaded bolt 544, which joins the positioning key 528 to the innerpatch member 520. With the interior corners 516 of the glass pieces402-424 placed between the outer member 518 and the inner member 520 andthe positioning key 528 in the patch space 526, the glass pieces 402-424may be adjusted until in a desired position before the retainingelements 534 and 544 are secured to the respective members 518 and 520and the glass pieces 402-424 fixed in place to establish a ridge for thebuilding to which the skylight is applied.

Spaces 546 between the peak sides 440 of glass pieces 402-424 at thepeak of the skylight between respective ones of the apex patch fittings428-436, as well as space 548 between apex patch fitting 428 and thefirst edge support 452 and space 550 between apex patch fitting 436 andsecond edge support 454 are sealed with the ridge sealing component 446that includes an interior trim gasket 554 and a backer rod 556. The trimgasket 554 and the backer rod 556 extend substantially the lengths ofspaces 546-550. The trim gasket 554 is made of a relatively softmaterial, such as rubber having a hardness of about 70 Shore Adurometer. The trim gasket 554 is a shaped piece including flexible legs558 that, with the softness of the material, ensures that the gasket 554remains in substantial contact with ends 560 and 562 of adjacent piecesof glass even if the space and/or angles between vary to an extent fromone end to the other of the spaces 546-550. The gasket 554 may befabricated of other materials and of different shapes as long as thatgap filling element takes up the area of the spaces 546-550 between theinner portions of adjacent pieces of glass sufficiently to provide areasonable thermal seal.

The backer rod 556 is used to fill a portion of the space 546-550 inmiddle and outer regions between the adjacent pieces of glass with aninsulative material that provides a substrate for a sealing material,such as silicone, to provide an outer seal 564 of the ridge sealingcomponent 446.

The system 400 further includes components to secure and seal theskylight at the ends of the ridge-shaped skylight, which ends may alsobe referred to herein as the edges. Adjacent ones of the edge supportsections 498 meeting at end peak 566 establish an edge support interface568. The edge support interface 568 extends from an upper interface area570 to a lower interface area 572. Adjacent sill members 458 of the edgesupport sections 498 are mechanically joined together with an edgesplice plate 574 and mechanical connectors such as threaded bolts 576adjacent to where mechanical connectors such as threaded bolts 578 jointhe sill members 458 to the underlying surface 472. The edge spliceplate 574 spans the edge support interface 568 and is joined to each ofthe adjacent still members 458. The edge splice plate 574 is an angledplate wherein the angle is determined by the desired slope of the roofof the building to which the system 400 is applied. The upper interfacearea 570 is sealed with the ridge sealing member 552 or, alternatively,with a sealing material as described herein. The lower interface area572 is sealed with a sealing material, such as silicone, or anothermaterial suitable to minimize thermal and moisture intrusion to theunderlying surface 472.

The system 400 also includes arrangements for sealing space 580 betweenadjacent ones of the base support sections 456. Specifically, adjacentsill members 458 of the base support sections 456 are mechanicallyjoined together with a sill splice plate 581 and mechanical connectorssuch as threaded bolts 582 adjacent to where the threaded bolts 478 jointhe first leg 464 of the sill member 458 to the underlying surface 472.The sill splice plate 581 spans the sealing space 580 wherein the sillmembers 458 meet. The sealing space 580 is sealed with a sealingmaterial, such as silicone, or another material suitable to minimizethermal and moisture intrusion to the space under the glass pieces402-424. Further, space 584 between adjacent glass pieces 402-424 awayfrom the peak of the skylight are sealed with the ridge sealing member26 described herein with respect to system 10. The description of theridge sealing member 26, including reference to the trim gasket and thebacker rod, is incorporated here with respect to the arrangement andfunction of the ridge sealing member for the space 584.

Those skilled in the art will recognize that a single-slope skylight maybe fabricated with some of the components used to make the ridge-shapedskylight of the system 400. Such a single-slope skylight would have asingle set of glass pieces sharing the same plane with the roof of abuilding. The base sides and opposing sides of the glass pieces would besupported, secured and sealed in the manner described herein withrespect to the first base support 448, the first edge support 452 andthe second edge support 454. Truncated apex patch fittings like apexpatch fittings 428-436 may be employed to secure the sides of the glasspieces and adjacent glass pieces may be joined and sealed with respectto one another as described with respect to the system 400.

The hipped ridge-shaped skylight formed of the skylight system 600represented in FIGS. 27-37 includes eight rectangularly-shaped glasspieces 602-616, two isosceles-shaped glass piece 618 and 620, and fourright triangle-shaped 12 pieces of glass 624-630. The system 600 alsoincludes ridge base support sections 632, end base support sections 634and transition base support sections 636. While shown having eightrectangularly-shaped glass pieces, the skylight of the system 600 mayhave more or fewer such pieces and so, accordingly, the length of theskylight is not limited to the dimensions associated with the specificnumber of glass pieces shown. Longer skylights of hipped ridge designare possible with the present invention.

The eight glass pieces 602-612 are positioned on underlying surface 638and affixed thereto at their base sides 640 with the ridge base supportsections 632 used to fix them in place on the surface 638 in the samemanner as described herein with respect to the base support sections 456of system 400. The description of that arrangement is incorporatedherein by reference with respect to placement and joining of glasspieces 602-616. Interior corners 642 of peak sides 644 of the glasspieces 602-616 are joined together with first apex patches 646-650 inthe same manner as described herein with respect to the apex patchfittings 428-436 of system 400. The description of that arrangement isincorporated herein by reference. Further, peak spaces 652 between thepeak sides 644 and between respective apex patches 646-650, as well aspeak spaces 652 between first apex patch fitting 646 and second apexpatch fitting 654 and between first apex patch fitting 650 and secondapex patch fitting 656 are sealed in the same manner as described withrespect to the sealing of spaces 546 of the system 400. The descriptionof that arrangement is incorporated herein by reference. Yet further,spaces 658 between sides 660 of adjacent pieces of glass 602-616 aresealed in the same manner as described with respect to the sealing ofthe equivalent spaces of the system 400.

The two glass pieces 618 and 620 are positioned on underlying surface638 and affixed thereto at their bases 662 with the end base supportsections 634 used to fix them in place on the surface 638 in the samemanner as described herein with respect to the base support sections28-34 of system 10. The description of that arrangement is incorporatedherein by reference with respect to placement and joining of glasspieces 618 and 620.

The four glass pieces 624-630 are positioned on underlying surface 638and affixed thereto at their bases 663 with the transition base supportsections 636 used to fix them in place on the surface 638 in the samemanner as described herein with respect to the base support sections28-34 of system 10. The description of that arrangement is incorporatedherein by reference with respect to placement and joining of glasspieces 618 and 628.

Peaks 664 and 666 of glass pieces 618 and 620 are joined together withpeaks 668-674 of glass pieces 624-630 and with exterior corners 675 ofglass pieces 602, 608, 610 and 616 using second apex patch fittings 654and 656.

Each of the second apex patch fittings 654 and 656 includes an outerpatch member 676 and an inner patch member 678 establishing a patchspace 680 therebetween. An underside 682 of the outer patch member 676and an upper side 684 of the inner patch member 678 includes an apexpatch fitting gasket 686 affixed thereto. The distance between thegasket 686 of the outer patch member 676 and the gasket 686 of the innerpatch member 678 is determined by the thickness of the glass pieces 602,608, 610, 616, 618 and 624-630. The apex patch fitting members 676 and678 are joined together with joining members such as threaded bolts 700and 710 in the manner described with respect to other apex patchfittings of the invention.

The apex patch fitting members 676 and 678 are sized and shaped toaccept and retain therein peaks of the three different types of glass ofthe system 600. In particular, the members 676 and 678 include twoopposing transition sections 688 and 690 and an end section 692. Theopposing transition sections 688 and 690 of the outer patch member 676and the inner patch member 678 are configured to receive and retaintherebetween the exterior corners of the rectangular shaped glass pieces602, 608, 610 and 616, and the peaks of the transition glass pieces624-630. The end sections 692 of the outer patch member 676 and theinner patch member 678 are configured to receive and retain therebetweenthe peaks of the end glass pieces 618 and 620.

The patch space 680 is further established by a plurality of patchpositioning keys 694. The patch positioning key 694 is a shaped elementhaving an upper section 696 and a lower section 698. The upper section696 is essentially in the form of an annulus, with a pilot hole interiorfor receiving a retaining element such as threaded bolt 700, which joinsthe positioning key 694 to the outer patch member 676. In a manner aspreviously described with respect to other patch positioning keys ofother apex patch fittings. The lower section 698 is trapezoidal in shapeso that its perimeter 702 is substantially in parallel with inner peaksection 704 of the exterior corners 676 of the peak sides of the glasspieces 402-424 and spaced therefrom by flexible patch block 706. Thelower section 698 also has a port 708 for retaining therein a retainingelement such as threaded bolt 710, which joins the positioning key 694to the inner patch member 678. With the exterior corners 675 of theglass pieces 602, 608, 610 and 616, and the peaks of glass pieces618-630 placed between the outer member 676 and the inner member 678 andthe positioning key 694 in the patch space 680, the glass pieces may beadjusted until in a desired position before the retaining elements 700and 710 are secured to the respective members 676 and 678 and the glasspieces fixed in place.

Interfaces between adjacent pieces of glass may be joined and/or sealedas previously described herein with respect to other glass interfaces ofsystems 10, 200 and 400. For example, the ridge sealing component 446may be used to seal ridge interfaces 712 between peak sides of adjacentglass members 602-616 at the peak and a similar form of it may be usedat hip interfaces 714. Further, as noted, spaces between adjacent piecesof glass at the sides thereof may be sealed in the manner describedherein with respect to other adjacent pieces of glass located on thesame plane.

An example method of making a skylight is described with respect toFIGS. 38-41. The figures illustrate primary steps for makingpyramid-shaped skylight; however, it is to be understood that similarsteps may be used to make skylights of other shapes. In the method, asupport frame 1000, such as the support frame 18 of system 10, isaffixed to a substrate 1002. Next, a first apex patch fitting retainerjig 1004 and a second apex patch fitting retainer jig 1006 are placed,but not secured, on opposing sills 1008 and 1010 of the support frame1000. Each of the jigs 1004 and 1006 includes a base 1012/1014 arrangedto contact and be on the sills 1008 and 1010 and butted up againstsetting chairs 1016 and 1018 of those sills 1008 and 1010. When the jigs1004 and 1006 are placed on the support frame 1000, the bases 1012 and1014 are substantially centered on the sills 1008 and 1010,respectively.

The jig 1004/1006 further includes a body 1020/1022 extendingsubstantially from the center of the base 1012/1014 at or close to aright angle. The body 1020/1022 terminates with a head 1024/1026approximating in dimensions the peak of a piece of glass that is to formpart of the skylight. The head 1024/1026 may be triangular as shown, aspart of the process of making a pyramid-shaped skylight, or it may be ofa different shape dependent on the particular skylight's shape. Forexample, it may be square for a ridge-shaped skylight or trapezoidal fora hipped ridge. The length of the body 1020/1022 is adjustable toaccount for glass pieces of different sizes.

With the heads 1024 and 1026 held up so that the bases 1012 and 1014 ofthe respective jigs 1004 and 1006 are substantially flat to the angledsills 1008 and 1010, lower member 1028 of an apex patch fitting of thetype describe herein with respect to the system 10, is positioned underthe respective heads 1024 and 1026 and the heads 1024 and 1026 arelowered until they rest on a portion of upper surface 1030 of the lowermember 1028. As shown in FIG. 39, one or more patch positioning keyssuch as patch positioning key 106, are joined to the lower member 1028and extend from a surface thereof. The heads 1024 and 1026 of the jigs1004 and 1006 make contact with and squeeze the patch positioning keys.In this condition, the lower member 1028 is suspended above thesubstrate 1002 effectively centered with respect to the support frame1000. The opposing jigs 1004 and 1006 resting on sills 1008 and 1010 andagainst setting chairs 1016 and 1018 create a squeezing compressiveforce on the patch positioning keys joined to the lower member 1028 thatkeeps the lower member 1028 in a fixed position suspended above thesubstrate, with a portion of the upper surface 1030 of the lower member1028 covered by the jigs 1004 and 1006 as shown. The downward pressureassociated with gravity ensures that the lower member 1028 remains inthat position. Any additional downward force on the jigs 1004 and 1006further forces the jigs 1004 and 1006 together and thereby furthersecures the lower member 1028 suspended in place.

With the lower member 1028 suspended in place, bases 1032 and 1034 oftwo pieces of glass 1036 and 1038 are placed on opposing sills 1040 and1042 of the support frame 1000 and peaks 1044 and 1046 of the glasspieces 1036 and 1038 are placed on the portions of the upper surface1030 of the lower member 1028 not covered by the jigs 1004 and 1006;that is, in spaces adjacent to the heads 1024 and 1026 of the jigs 1004and 1006. With the glass pieces 1036 and 1038 so placed, peaks of theglass pieces 1036 and 1038 make contact with and squeeze the positioningkey, thereby also ensuring suspension of the lower member 1028 as aresult of that squeezing of the one or more positioning keys attached tothe lower member 1028. With the glass pieces 1036 and 1038 sopositioned, the jigs 1004 and 1006 can be removed and the lower member1028 will remain in position, secured by the opposing downward forces ofthe opposing glass pieces 1036 and 1038 resting thereon. The removedjigs 1004 and 1006 may then be replaced on the lower member 1028 byremaining glass pieces 1048 and 1050 placed on the support frame 1000.Upper member 1052 of the apex patch fitting is then placed on the peaksof all of the glass members 1036, 1038, 1048 and 1050 and secured inplace using a plurality of patch positioning keys 1054 such as the patchpositioning keys 106 and the threaded bolts 104 of system 10, as well asthe other joining components described herein. The glass pieces 1036,1038, 1048 and 1050 are secured to the support frame 1000 as describedherein and all interfaces sealed as described herein.

The present invention includes a kit for building and installing askylight of selectable shape and dimensions. The kit includes thecomponents described herein, although it may or may not include theglass pieces, which may be of custom size. The kit at least includes oneor more apex patch fitting suitable for the desired skylight design, thesupport frame with accompanying hardware including one or more optionalsetting chairs, and the ridge sealing components. The kit may furtherinclude one or more of the apex patch fitting retainer jigs. The kitincludes instructions for making/installing the skylight substantiallyin accordance with the method described with respect to FIGS. 38-41,which instructions may be adjusted to account for the particular sizeand shape of the desired skylight.

It is to be understood that various modifications may be made to thesystem 10 and the components described herein without departing from thespirit and scope of the invention. Accordingly, other embodiments arewithin the scope of the claims appended hereto.

What is claimed is:
 1. A method for making a skylight comprising thesteps of: a. securing a skylight support frame to a substrate; b.placing two opposing apex patch fitting retainer jigs on the supportframe; c. suspending a lower member of an apex patch fitting between theopposing retainer jigs, wherein the lower member is coupled to one ormore positioning keys extending from the lower member such that theopposing retainer jigs contact and squeeze the one or more positioningkeys to suspend the lower member therebetween with portions of the lowermember covered by the opposing retainer jigs and other portions of thelower member not covered by the opposing retainer jigs; d. placing twoopposing glass pieces on the support frame and on the other portions ofthe lower member of the apex patch fitting so that the two opposingglass pieces contact and squeeze the one or more positioning keys tosuspend the lower member therebetween; e. removing the retainer jigsfrom the support frame and from the lower member; f. placing one or moreremaining glass pieces on the support frame and on the lower member ofthe apex patch fitting where the retainer jigs have been removed; g.securing with the one or more positioning keys an upper member of theapex patch fitting to the lower member to retain the glass piecestherebetween; and h. sealing each of the glass pieces to the supportframe, the apex patch fitting and to adjacent ones of the glass pieces.2. The method of claim 1 wherein the support frame includes a sill and asetting chair and wherein the steps of placing the retainer jigs and theglass pieces on the support frame include placing the retainer jigs andthe glass pieces on the sill and butting them against the setting chair.3. The method of claim 2 wherein a plurality of setting blocks arepositioned between the setting chair and the glass pieces.
 4. The methodof claim 1 wherein a plurality of apex patch fittings are used to retainthe glass pieces.
 5. The method of claim 1 wherein the step of sealingincludes the step of inserting a ridge sealing component at theinterfaces of adjacent pieces of glass.
 6. The method of claim 1 whereinthe upper member and the lower member are of substantially the sameshape and orientation with respect to one another.
 7. The method ofclaim 1 wherein each of the one or more patch positioning keys includesan upper section and a lower section, wherein the upper section isjoined to the upper member of the apex patch fitting and the lowersection is joined to the lower member of the apex patch fitting.
 8. Themethod of claim 7 wherein the upper section of the patch positioning keyhas an annular shape.
 9. The method of claim 7 wherein the lower sectionof the patch positioning key has a trapezoidal shape.